SILICON NITRIDE PASSIVATION WITH AMMONIA PLASMA PRETREAMENT FOR IMPROVING RELIABILITY OF AlGaN/GaN HEMTs

ABSTRACT

This invention pertains to an electronic device and to a method for making it. The device is a heterojunction transistor, particularly a high electron mobility transistor, characterized by presence of a 2 DEG channel. Transistors of this invention contain an AlGaN barrier and a GaN buffer, with the channel disposed, when present, at the interface of the barrier and the buffer. Surface treated with ammonia plasma resembles untreated surface. The method pertains to treatment of the device with ammonia plasma prior to passivation to extend reliability of the device beyond a period of time on the order of 300 hours of operation, the device typically being a 2 DEG AlGaN/GaN high electron mobility transistor with essentially no gate lag and with essentially no rf power output degradation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 11/311,592, filed Dec. 9, 2005.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention pertains to improving reliability of heterojunctiontransistors, particularly high electron mobility transistors, with anammonia plasma pretreatment prior to passivation.

2. Description of Related Art

Prior methods which have been used to prepare processed AlGaN/GaN highelectron mobility transistors (HEMTs) for reliable operation in the pasthave included using no passivation at all, or direct deposition of avariety of electrically insulating materials intended to passivatesurface states. These material films can be deposited by such processesas plasma enhanced chemical vapor deposition. Silicon nitride (SiN) isone of the most commonly used surface passivating films for AlGaN/GaNHEMTs and can be deposited onto the device by the aforementioned method.However, silicon nitride passivation, while an improvement over nopassivation at all, still results in a decrease in performance of thedevice after dc and rf bias stress. This is a significant limitation anddisadvantage in the reliability of AlGaN/GaN HEMT electronic devices.

AlGaN/GaN high electron mobility transistors have shown exceptionalmicrowave power output densities, with a recently reported continuouswave power density of 30 W/mm and 50% power added efficiency at afrequency of 8 GHz, In addition, a 36-mm gate-width GaN HEMT has beendemonstrated with a total power output of 150 W and a power addedefficiency of 54%. However, device reliability remains a major concernfor III-N HEMTs. In AlGaN/GaN HEMTs, degradation of the dc, transient,and microwave characteristics are often seen after relatively shortperiods of normal device operation. Although reliability is improving,microwave power output typically degrades by more than 1 dB in less than1000 hours of operation.

OBJECTS AND BRIEF SUMMARY OF THE INVENTION

It is an object of this invention to pretreat an AlGaN/GaNheterojunction field effect transistor with ammonia plasma prior topassivation in order to improve reliability thereof.

Another object of this invention is to pretreat an AlGaN/GaN transistorwith a low-power ammonia plasma prior to silicon nitride deposition forhigh power applications.

Another object of this invention is to improve reliability of anAlGaN/Gan transistor adapted for use in radars and communicationequipment.

Another object of this invention is to improve reliability of AlGaN/GaNHEMTS characterized by the presence of 2 DEG channel.

Another object of this invention is prevention of drain current collapsecaused by electron traps.

Another object of this invention relates to reduction of surface andbulk traps in high power and high electron mobility AlGaN/GaNheterojunction transistors that can potentially operate at voltagesexceeding 100 volts and with electron mobility in excess of 1000 cm²/vsec.

These and other objects of this invention can be attained bypretreatment of a 2 DEG AlGaN/GaN heterojunction transistor with alow-power ammonia plasma prior to passivation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional schematic representation of a high mobilitytransistor with AlGaN, GaN and doped GaN layers deposited on a siliconcarbide substrate.

FIGS. 2 (a) and (b) show induced current collapse of unpassivated HEMTin (a) before stress and after stress and in (b) of passivated HEMTdevices with silicon nitride only and with silicon nitride passivation,stressed for 60 hours and 176 hours, respectively.

FIG. 3 is a plot of normalized Drain Current versus Time, showing draincurrent response to pulsed gate voltage, in (a) with no passivation; in(b) for the same device after 64-hour stress; in (c) silicon nitridepassivated device after 80-hour stress; and in (d) a device pretreatedwith ammonia plasma and passivated with silicon nitride, after 176-hourstress.

FIG. 4 is a plot of power _P_(out) versus Time showing rf outputdegradation of (a) passivated device with silicon nitride only and (b)pre-treated with ammonia plasma and coated or pre-treated with siliconnitride wherein stress conditions were 20v, 200 mA/mm operated at 2 GHzat 1 dB compression of the gain.

DETAILED DESCRIPTION OF THE INVENTION

The purpose of this invention, in a preferred embodiment, is to improvethe reliability of aluminum gallium nitride/gallium nitride (AlGaN/GaN)high electron mobility transistors by incorporating an ammonia (NH₃)plasma pre-treatment prior to silicon nitride (SiN) passivation of theheterojunction transistors after all other processing has beencompleted.

This invention pertains to an electronic device and to a method formaking it. The device is a heterojunction transistor, particularly ahigh electron mobility transistor characterized by the presence of a 2DEG channel. Transistors of this invention contain an AlGaN barrier anda GaN buffer, with the channel disposed, when present, at the interfaceof the barrier and the buffer. The method pertains to treatment of thedevice with ammonia plasma prior to passivation to extend reliability ofthe device beyond a period of time on the order of 300 hours ofoperation, the device typically being a 2 DEG AlGaN/GaN high electronmobility transistor with essentially no gate lag and with essentially norf power output degradation.

Pursuant to one embodiment of the method, an in-situ ammonia plasmatreatment is used before a silicon nitride deposition on an Al_(x)Ga_(1-x)N/GaN (where x is 0.20 to 0.30), after all other processing hasbeen completed. The ammonia plasma pretreatment and the silicon nitridedeposition can both be performed in a plasma enhanced chemical vapordeposition system. The substrate temperature is maintained at 250° C.for both. For the ammonia plasma pretreatment, a relatively low 35 Wpower level is typically used. An example of resulting processparameters are 200 mT chamber pressure, 400 sccm N₂+SiH₄ (95:5) gasflow, 9 sccm ammonia gas flow, 35 W ICP power, and OW RIE power. Asilicon nitride film thickness of 750 A is adequate, with an opticalindex (n) of approximately 2.0, which indicates the approximatecomposition of the Si₃N₄ passivation layer.

The nitride deposition process was performed after all of the processingsteps and was followed by etching openings to the metal contacts anddeposition and patterning of a Ti—Au overlay metal. The ammonia plasmapretreatment and the silicon nitride deposition were performed in aninductively coupled plasma (ICP) configured plasma-enhanced chemicalvapor deposition system with a bottom electrode diameter of 8 inches.The silicon nitride film, using about 5% by volume SiH₄ in a balance ofN₂, was formed using a SiH₄:NH₃:N₂ plasma recipe (N₂+SiH₄ of 300 to 400sccm; NH₃ of 9 to 16 sccm). The substrate temperature was maintained at250° C. for both the ammonia plasma pretreatment and the silicon nitridedeposition processes. The silicon nitride film thickness and therefractive index were measured by ellipsometry, and were 740-800 A and2.03-2.09, respectively, for different device runs. For thepretreatment, the chamber pressure was 50 mT and the duration was 180seconds. The ICP power was set to 35 W at 13.56 MHz, while the bottomelectrode was set to 0 W.

The invention can be described in connection with FIGS. 1-4 wherein FIG.1 shows a cross-sectional schematic transistor 10 containing barrierlayer 12 disposed on channel 14, which is followed by channel/bufferlayer 16, which in turn is disposed on buffer layer 17, and which inturn is disposed on substrate 18. The substrate supports all of thelayers of the transistor. The barrier layer is AlGaN and thebuffer/channel layer is GaN with the channel layer being at theinterface of the barrier and the buffer/channel layers. The channel hasa thickness on the order of 50 A to 100 A. It is the 2 DEG channel layerthat characterizes a high electron mobility transistor, with electronmobility being in excess of 1000 cm²/V sec. There is a layer of AlNbetween the buffer/layer and the substrate layers. The 2-DEG is formedat the interface of the buffer/channel and the barrier layers.

Completing the schematic transistor of FIG. 1 is contact 20 whichprovides electrical connection to source 24, barrier layer 12, andbuffer/channel layer 16. Likewise, contact 22 provides electricalconnection to drain 26, barrier layer 12, and buffer/channel layer 16.Source 24, drain 26, and gate 28 are disposed in top layer 30. Purposeof the source is to provide electrons to the transistor device. Theseelectrons flow through the interface 2 DEG between the barrier layer andthe buffer/channel layer to the drain. The gate controls the flow ofthese electrons through the 2 DEG. The source, the drain and the ohmiccontacts 20, 22, 24 and 26 are typically Ti—Al—Ni—Au and the gate istypically Ni—Au. Typical barrier layer thickness is 200 A 300 A, typicalchannel layer thickness is 50 A to 100 A, typical buffer/channel layerthickness is 1 μm to 3 μm, typical buffer layer thickness is 500 A to1500 A and typical substrate thickness is 1 μm to 2 μm.

Shown in FIGS. 2 (a) and (b) are the measured drain current for threeconsecutive sweeps of V_(DS) from 0 to 30V with V_(GS) held at 0 V. Thecharacteristics in FIG. 2 (a) are for an AlGaN/GaN HEMT without siliconnitride passivation prior to dc bias stress. For the non-stressed device(solid lines), the three traces are nearly coincident, as they shouldbe. But after dc bias stress for 64 hours with V_(DS)=30V and I_(DS)=200mA/mm (dashed lines), the second and third traces depart significantlyfrom the first trace. This reduction in drain current for the second andthird traces is due to trapped charge in the structure as a result ofhot electron injection caused at high drain voltages during the firstsweep. This effect is present in the device after stress due to thegeneration or activation of defects during the 64 hour dc bias stress.It can be see in FIG. 2 (b), that a silicon nitride passivation layerdoes little to suppress this effect (dashed lines). But the key result,shown in the solid lines, is that an ammonia plasma treatment prior topassivation completely eliminates this effect for at least 176 hours ofbias stress.

Corresponding results are seen with gate lag measurements as shown inFIGS. 3 (a-d). The gate lag measurements are for V_(DS)=1 V andV_(GS)=V_(TH)−2 V, pulsed to V_(GS)=0 V. The drain current pulse shownin each figure is normalized to the steady state value of drain current.The ideal response characteristic is for the pulsed current to rise tothe steady state value, as shown in FIG. 2 (d). Only the ammonia plasmaplus silicon nitride processed device shows the ideal characteristicafter bias stress. These characteristics again indicate that additionaltrapping levels are present after dc bias stress and that the ammoniaplasma step is effective in suppressing their generation.

The radio frequency (rf) degradation rate, in dB/hour, is also improvedby more than 100 times for the ammonia pretreated sample as compared todevices on the same split wafer with silicon nitride only. FIG. 4 showsthe change in Pout, normalized to its initial value, versus hours of rfbias stress. The pre-treated device shows little drop to 70 hours with aPin of 7 dBm, while the silicon nitride only device is degrading in thefirst 16 hours at Pin of 5 dBm, then even more rapidly after Pin wasincreased to 7 dBm.

An added benefit of the invention is believed to be that the ammoniaplasma provides hydrogen (H) atoms at the AlGaN surface. Passivation ofsurface defects by hydrogen has been used extensively in the past forsilicon and gallium arsenide technologies. Hydrogen has been found topenetrate well into the AlGaN and reduce the density of bulk n-AlGaNdeep level traps. These traps are thought to play a leading role in thecurrent collapse phenomena.

Ammonia plasma ionizes gas into charged particles that cause the surfaceto be cleaned and/or charged, as is well known. The chamber used hereinfor ammonia plasma treatment was a typical for semiconductor equipmentmanufacturers. Treatment duration was 3 minutes, although it can behigher or lower, but is typically in the range of 3-5 minutes. Otherparameters that may be used to produce the desired ammonia plasmainclude power of 10-35 watts, ammonia flow rate of 30 to 70 sccm. Plasmafrequency is 13.56 MHz.

Rf stress conditions included conditions for dc bias and a microwavesignal that goes into the device. The input power of this signal istypically 10-15 dBM at a frequency of 2-12 GHz. The dc stress conditionsinclude drain voltage typically of 20-30 volts and a drain currenttypically of 100-300 mA/mm.

In conclusion, reliability of AlGaN—GaN high eletron mobilitytransistors that exhibit induced trapping effects due to extended dcbias or microwave operation has been improved by the incorporation of anammonia plasma treatment prior to passivation. This processing stepsuppresses increases in current collapse and eliminates gate lagreductions after extended dc bias and significantly lessens degradationunder microwave operation. It is believed that the interaction of theplasma with the exposed surface and H ions and/or atoms diffusion intothe epitaxial layers are responsible for the improved devicecharacteristics after extended dc bias and microwave operation.

While presently embodiments of the invention have been shown of thenovel transistors and treatment with ammonia plasma, and of the severalmodifications discussed, persons skilled in this art will readilyappreciate that various additional changes and modifications can be madewithout departing from the spirit of the invention as defined anddifferentiated by the following claims.

1. A high electron mobility transistor, comprising: a substrate; a GaNbuffer layer disposed on the substrate; an AlGaN barrier layer disposedon the GaN buffer layer such that a 2 DEG channel is disposed at theinterface of the AlGaN barrier layer and GaN buffer layer; and apassivation layer disposed on the AlGaN barrier layer, wherein an uppersurface of the AlGaN barrier layer has been pre-treated with an ammoniaplasma prior to a deposition of the passivation layer.
 2. The transistorof claim 1, wherein the transistor has essentially no measurable draincurrent collapse for up to about 176 hours of dc bias stress.
 3. Thetransistor of claim 1, wherein the transistor has essentially nomeasurable gate lag for up to about 176 hours of dc bias stress.
 4. Thetransistor of claim 2, wherein the dc bias stress is characterized by adrain current of 100-300 mA/mm and a drain voltage of about 23-30 volts.5. The transistor of claim 2, wherein the dc bias stress is provided bya microwave signal having an input power P_(in) of 5-20 dBm at afrequency of 2-12 GHz.
 6. The transistor of claim 1, wherein the AlGaNbarrier layer is about 150 A to 300 A thick.
 7. The transistor of claim1, wherein the GaN buffer layer is about 5000 μm to 15,000 μm thick. 8.The transistor of claim 1, wherein the transistor has experiencedessentially no decrease in rf power output (P_(out)) up to about 70hours.
 9. The transistor of claim 1, wherein the AlGaN barrier layer ismade from Al_(x)Ga_(1-x)N, wherein 0.15≦x≦0.40.
 10. The transistor ofclaim 1, wherein the rate of degradation of microwave power output,while under continuous microwave operation, is at least 100 timessmaller than a conventional high electron mobility transistor that isnot pre-treated with ammonia plasma.
 11. The transistor of claim 1,wherein the transistor has electron mobility in excess of 1000 cm²/Vsec.
 12. The transistor of claim 1, further comprising a AlN bufferlayer disposed between the GaN buffer layer and the substrate.